Our Solutions
Manufacturing quality control that protects your bottom line
Smarter systems. Fewer defects. Real results.
As your company probably recognizes, quality issues in manufacturing aren’t just frustrating, they’re expensive.
According to data focused on assessing the cost of quality to manufacturers in 2024, 73% of surveyed manufacturers experienced at least one recall in the past five years, costing companies close to $100M per recall on average.
While most manufacturers rely on manual inspections, these inspections often slow down production, let defects slip through, increase costly rework, and are not scalable. Not to mention, inconsistent processes create massive compliance risks and lead to a drop in customer satisfaction.
The solution? A smarter, more automated approach to quality control in manufacturing.
At Live Solutions, our systems and approach help you catch defects before they happen. By implementing automated quality control systems and data-driven quality assurance processes, we partner with you to deliver reliable, scalable solutions that actually work.
With 75+ years of hands-on manufacturing experience, we don’t just recommend solutions in a vacuum or push our preferred vendors to your door, we work alongside your team to design, source, implement, and optimize quality control systems and strategies that help you sleep better at night.
The cost of “good enough” quality
Let’s be real.
Settling for “good enough” when it comes to quality control doesn’t just mean a few bad products. It leads to:
- Customer complaints that damage your reputation
- Expensive rework and waste that eat into profits
- Regulatory compliance risks that slow down production
- Delayed shipments that hurt customer relationships
- Brand-wide recalls that destroy consumer confidence
If you’re relying on human-driven or outdated quality control processes, you are likely losing thousands of dollars and risking a significant impact on your efficiency every day.
Omar Chavez
GAMT Engineering Manager, PPG Aerospace
Brian Sisk
Chief Technology Officer, Sepion Technologies
No Tech Debt. No Overwhelm. Just Measurable Progress.
Fixing it doesn’t have to be complicated. We know most manufacturers aren’t running digital twins or AI-ready production lines—and that’s okay. Our phased approach meets you at your current maturity level, delivering immediate wins while laying groundwork for scalable transformation.
Phase 1
Baseline & Bottleneck Mapping
Fix the basics before layering tech
- Manual Process Audits: Time-motion studies and operator interviews to map defect hot spots
- Paper Trail Forensics: Analyze manual inspection logs, rework tickets, and customer complaints to identify recurring failure patterns
- Gemba Walks: Floor-level observation sessions to spot workflow disconnects
We develop a prioritized list of quick fixes that effectively reduces defects within 30 days of implementation by simply aligning your team with our findings and implementing thoughtful solutions to support these findings.
Phase 2
Barely There Automation
Low-risk tools with high ROI
- Barcode-Driven Traceability: $500 handheld scanners to replace manual data entry, slashing transcription errors and starting down the path of your digital transformation
- DIY Dashboard Setup: Leveraging readily accessible templates to visualize scrap rates by shift, machine, or operator – no coding needed
- Foolproof Fixtures with the Lean Manufacturing Mindset: Mechanical poka-yoke devices to prevent assembly mistakes
Once we start, we will semi-automate your quality control, cutting paperwork and speeding up defect root-cause analysis to create agility and empower your team to make decisions in real-time.
Phase 3
Targeted Tech Pilots
Prove value before scaling
- Modular Vision Systems: Starting with targeted implementations using off-the-shelf cameras and simple programmable defect tracking
- Sensor Scale Up: Pilot critical equipment data gathering with vibration and temperature sensors to baseline the state of your assets to help predict future failures
- Growing Toward AI Maturity: Use Excel-based regression analysis to predict defect drivers to build the road to machine learning or AI implementation
We will engage our technology partners to help launch a tech pilot on your lines with quantified results to secure stakeholder buy-in and ease your transition to elevating your quality systems before we take the next step.
Phase 4
Scalable Systems
Ramping up your digital readiness
- Plug-and-Play IIoT: Pre-configured edge devices that stream OEE data to cloud dashboards without overhauling your entire line
- Phased AI Rollout: Start with rule-based automation before introducing advanced automated data aggregation tools
- Legacy Machine Upgrades: Add HMIs, upgrade PLCs, and upgrade mechanical systems in ageing equipment for real-time SPC – no equipment replacement required
We can work toward our Industry 4.0 executable roadmap by developing a customizable Quality 4.0 roadmap that aligns tech adoption with your team’s capacity and budget cycles, while focusing on real results within your quality organization.
The Live Solutions approach to next-level quality control
Your future state will combine a mix of automation, AI, and deep manufacturing expertise to catch defects early, optimize production quality management, improve overall manufacturing inspection processes, and help educate your employees on the impact and cost of quality.
AUTOMATED INSPECTION SYSTEMS
AUTOMATED INSPECTION SYSTEMS
Speed, accuracy, and consistency, all without human error.
We integrate vision systems, sensor-based quality checks, and AI-driven inspection points throughout your production line.
The Result?
Faster defect detection
Fewer errors
Higher production efficiency
MACHINE DRIVEN QUALITY CONTROL LAYERED WITH HUMAN EXPERTISE
MACHINE DRIVEN QUALITY CONTROL LAYERED WITH HUMAN EXPERTISE
Turn inspection data into real-time quality insights.
Your factory generates tons of quality data—but are you using it effectively? Our team works with the leading technology providers to design systems that track trends, identify quality risks, and predict potential defects before they cause major problems.
With AI-powered analytics, our collaboratively designed systems help you optimize production quality management, reducing waste, labor hours, and improving consistency.
Unlike system programmers or software providers, we bring deep manufacturing expertise to the table. We understand what manufacturers need because we are manufacturing experts. Our approach ensures you get it right the first time—saving on implementation costs while aligning your team for success. Let us guide you toward smarter quality control and operational excellence.
Example Services Offered
Real-time quality data analytics and reporting
Advanced defect detection programming
Automated data analytics and root cause identification
IoT-enabled quality monitoring systems
Statistical process control (SPC) implementation
Continuous improvement through quality data insights
COMPLIANCE & DOCUMENTATION
COMPLIANCE & DOCUMENTATION
We ensure your quality control systems meet industry standards and regulatory requirements. Through automated documentation and reporting, we create audit-ready processes that protect your business and satisfy customer requirements.
Example Services Offered
Digital documentation management systems
Regulatory compliance gap analysis and consulting
Automated audit trail creation and management
Standard operating procedures (SOPs) development
Real-time compliance monitoring solutions
Document control system integration with QMS
INTEGRATED QUALITY CONTROL PROCESSES
INTEGRATED QUALITY CONTROL PROCESSES
Build a production line that doesn’t cut corners.
We work directly with your team to design customized quality control programs that:
- Reduce defects and rework costs
- Maintain consistency across all production shifts
- Fit seamlessly into your existing manufacturing processes
Customized, Not Cookie-Cutter
We design systems that adapt to your reality:
Mixed-Mode Lines: Balance automated checks with human oversight based on risk severity
Shift-Proof Standards: Digital work instructions with photo/video guides to ensure consistency across teams to prepare for next level training system implementations
Culture Upgrades
Quality EQ Training: Teach operators to interpret real-time defect data - turning inspectors into problem-solvers
Leadership Scorecards: Daily COPQ (Cost of Poor Quality) metrics that convert defects into profit-impact dollar figures
Ready to get started?
Get in touch with an industry 4.0 expert
“Helped us improve quality”
Live Solutions helped us deploy engineering tools including Failure Mode and Effects Analysis (FMEA) and problem solving (8D). Those formal processes helped us train our team members, improve quality of our products and prototypes, and increase overall productivity. Multiple team members described the FMEA process as ‘fun’, which was a first for me, and will be the example for how we deploy engineering processes in the future
Why Manufacturers Trust Live Solutions for Quality Control
75+ years of hands-on manufacturing experience
Lean Six Sigma Black Belt certified quality control experts
Proven expertise in digital transformation readiness and implementation execution
Experience with regulated industries: Aerospace, Medical, Pharmaceutical, Electronics, Chemical, Personal Care, Food & Beverage, and more
CESMII-certified Smart Manufacturing professionals
CESMII-certified Smart Manufacturing professionals
You shouldn’t have to waste time and money on defects, rework, and compliance headaches. Let’s streamline your quality control systems and protect your bottom line with smarter, automated solutions.
Let’s have a real conversation about fixing your quality challenges. No sales pitch, just solutions that work.
STOP CHASING DEFECTS. START PREVENTING THEM.
TRANSFORM YOUR QUALITY CONTROL STRATEGY
QUALITY DOESN’T IMPROVE BY CHANCE, IT IMPROVES BY DESIGN.
Whether you’re struggling with recurring defects, compliance challenges, or outdated inspection processes, we help you move from reactive fixes to proactive quality management.
- Cut rework costs with mistake-proofed workflows
- Reduce audit prep time by implementing digitized quality documentation, metrics, and reporting
- Slash customer complaints with real-time defect capture and trend analytics
With a tailored approach grounded in automation, analytics, and real-world manufacturing experience, Live Solutions helps you reduce rework, avoid costly recalls, and maintain production consistency, without sacrificing throughput or scalability.
Let’s take the uncertainty out of quality and build systems that protect your margins, your compliance, and your reputation. All it takes is a conversation and a willingness for change.